Apparatus for manufacturing ceramic microspheres for cementing applications

ABSTRACT

A method and apparatus for manufacturing ceramic microspheres from industrial slag. The microspheres have a particle size of about 38 microns to about 150 microns. The microspheres are used to create a cement slurry having a density of at least about 11 lbs/g. The resultant cement slurry may then be used to treat subterranean wells.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the U.S. divisional application of U.S. applicationSer. No. 12/327,831 filed Dec. 4, 2008, now U.S. Pat. No. 7,884,055.

BACKGROUND OF THE INVENTION

This invention relates to the application of industrial slags tomanufacture ceramic microspheres for use in cementing applications, moreparticularly, to the manufacturing of controlled size hollow, cellularand solid microspheres, which have latent pozzolanic properties as wellas weak magnetic properties, from blast furnace slags and industrialsteel furnace slags. The ceramic microspheres can be used forconventional cementing oil and gas well operations, for instance toreplace Portland Cement in mud-to-cement (MTC) technology and/or blastfurnace slag and also for the construction areas.

Portland cement is a hydraulic cement made by heating a limestone andclay mixture in a kiln and pulverizing the resulting material. The mostcommon use for Portland cement is in the production of concrete.Portland cement is also used in mortars, such as with sand and wateronly, for plasters and screeds, and in grouts, such as cement/watermixes squeezed into gaps to consolidate foundations, road-beds, etc.

Blast furnace slag (BFS) is a by-product produced in the manufacturingof iron, iron ore, iron scrap and limestone fluxes or dolomite fluxes.BFS is nonmetallic and consists primarily of silicates,alumninosilicates and calcium-alumina-silicates.

Industrial steel furnace slags (SFS) are a by-product in themanufacturing of steel and/or steel alloys. SFS is a nonmetallic productthat is developed simultaneously with steel in basic oxygen, electric,or open-hearth furnaces. It consists of calcium silicates and ferritescombined with fused and mineralogical combined oxides of iron, aluminum,manganese, calcium and magnesium.

In cementing applications, such as steam injection techniques and otheroil extraction processes that require increased well temperatures, thecementing material used must be able to withstand elevated temperatureand thermal cycling associated with steam flood. The conventionalPortland cement and also water based drilling fluids mixed with Portlandcement exhibit high thermal degradations. This degradation damages thewell resulting in repairs which increase operation costs. In steaminjection techniques, the use of ceramic microspheres in cementingapplications leads to a lightweight grout that is resistant to elevatedtemperatures and thermal cycling.

In some regions of the world where steam injection techniques areemployed, BFS is not readily available and is therefore imported. Thehigh costs associated with importing BFS compounded by the unknownheterogeneous chemical composition of the BFS, unknown remainingcrystalline phases in the BFS and the potential need for an additionalmilling process is a disadvantage suffered by regions of the world thatdo not produce BFS. By combining hollow microspheres of compositionsimilar to BFS, steam injection resilient lightweight grouts of lowdensity have been obtained.

The use of ceramic microspheres for cementing applications results insubstantial savings by reducing the environmental impact of thecementing application, reducing the consumption of oilfield cement andby replacing the need to import expensive cementing additives.

The ceramic microspheres for cementing applications of the presentinvention may replace BFS and/or Portland Cement in any well cementingoperation. The ceramic microspheres of the present invention are anadvantageous well cementing constituent that may be successfullyimplemented in differing temperature dependent processes, such as thesteam injection technique employed for heavy crude oil extraction.

SUMMARY OF THE INVENTION

The primary object of the present invention is the creation of hollow,cellular and solid microspheres, i.e. ceramic microspheres and/ormicrospheres, of a controlled size from blast furnace slag and steelfurnace slags. These novel ceramic microspheres exhibit latentpozzolanic properties as well as weak magnetic properties.

It is a further object of the present invention to provide a method ofmanufacturing ceramic microspheres from industrial slags for wellcementing applications.

It is yet a further object of the present invention to provide anapparatus for the manufacturing of ceramic microspheres from industrialslags.

In accordance with the present invention a method for manufacturingceramic microspheres is disclosed which comprises the steps of obtainingindustrial slag; manufacturing microspheres from the industrial slag,wherein the microspheres have a particle size of about 38 microns toabout 150 microns; and, using the microspheres to make a cement slurry,wherein the cement slurry has a density of at least about 11 pounds pergallon (lb/g).

In further accord with the present invention a method for treatingsubterranean oil and gas wells is disclosed comprising the steps ofobtaining industrial slag; manufacturing microspheres from theindustrial slag, wherein the microspheres have a particle size of about38 microns to about 150 microns; using the microspheres to make a cementslurry, wherein the cement slurry has a density of at least about 11lb/g (1318 kg/m3), and; deploying the cement slurry into a subterraneanwell.

Also in further accord with the present invention an apparatus formanufacturing microspheres from industrial slag is disclosed comprisinga vibration feeder, a glass bench burner, a first collection chamber,and a second collection chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of preferred embodiments of the present inventionfollows, with reference to the attached drawings, wherein:

FIG. 1 illustratively depicts the slag spheroidization device.

DETAILED DESCRIPTION

The invention relates to a method for the manufacturing of ceramicmicrospheres from spheroidized industrial slag.

Hereinafter the term “well” is used to refer to any one or all of thefollowing terms: reservoir, oil well, gas well, marginal well, stripperwell, i.e. any subterranean well and combinations thereof.

The ceramic microspheres of the present invention are granulatedmaterials with a small size and a spherical shape. Once used in acementing material, the microspheres impart high flowability to thecementing material. The microspheres are used in cement slurries, suchas oil well cement slurries, construction cement slurries, squeezecement slurries, cutting treatment cement slurries, as extenders andlight weight pozzolanic and viscosity reducing additives.

In the present disclosure, industrial slags, such as blast furnace slag(BFS), steel furnace slag (SFS) and other types of metallurgical slags,such as nickel, magnesium, copper and the like, are used to manufacturesolid, hollow, cellular and massive microspheres with a controlledparticle size of about 38 microns to about 150 microns.

Referring to FIG. 1, which depicts a slag spheroidization device, i.e.an apparatus for manufacturing microspheres from industrial slag. Themethod of manufacturing hollow, solid, cellular and/or massive ceramicmicrospheres begins with a ground industrial slag 16. Dependent upon themetallurgic origin of the industrial slag, the slag may have additionalmaterials, such as sulphur, carbon and/or water dissolved in thevitreous matrix. The slag may contain between 1% w/w to 10% w/w ofsulphur, less than 1% w/w of carbon and less than 1% w/w of water

The ground industrial slag 16 is fed into a vibration feeder 14.Vibration feeder 14 may be any device that is well known within the artthat is capable of moving volumes of bulk materials at either a fixed orvariable rate. As the industrial slag 16 exits vibration feeder 14 it iscontacted by a flame. The flame is supplied by a glass bench burner 12.The burner 12 propels a gas/oxygen mix flame of about 1200° C. to about2500° C. into the industrial slag 16 as it falls from vibration feeder14. The industrial slag 16 is molten by pyrolization 10 and spheroidized24 as it is propelled away from burner 12 at a rate of between about0.292 kg/h to about 0.368 kg/h.

The gas may be a natural gas, such as propane or butane, propylene,acetone, hydrogen, and/or a liquid fuel, such as petroleum or kerosene.The retention time of the industrial slag 16 in the flame is preferablybetween about 0.0001 s to about 0.008 s.

Continuing on FIG. 1, two collection chambers, first collection chamber20 and second collection chamber 30, are located adjacent to burner 12.The collection chambers may be any collection space within the art, suchas tubs, vats, vaults, etc., that is capable of withstanding the extremetemperatures employed in the spheroidization process.

As the pyrolized 10 particles are propelled by burner 12 in FIG. 1, theybegin to rapidly air cool and are spheroidized 24. The spheroidized 24industrial slag 16 of a coarser nature and higher density loses itsburner 12 propulsion at a faster rate. As a result, these coarserspheroidized 24 industrial slag 16 microspheres settle at a distancethat is closer to burner 12. The coarse microspheres 22 are collected inthe first collection chamber 20.

The first collection chamber 20 is directly connected to the hightemperature flame of burner 12 and is directly connected to the secondcollection chamber 30 at the opposite end.

When the spheroidized 24 industrial slag 16 of a finer nature and alower density is propelled from burner 12 in FIG. 1, it tends tomaintain its propulsion for a longer distance. As a result, these finerspheroidized 24 industrial slag 16 microspheres settle at a distancethat is further away from the burner 12. These fine microspheres 32 arecollected in the second collection chamber 30. The second collectionchamber 30 is attached to the first collection chamber 20 at theopposite end of burner 12.

The slag spheroidization device of FIG. 1 also provides openings for theflow of particles, gas and air. The first collection chamber 20 has anopening 40 to allow for the entrance of the propelled pyrolized 10industrial slag 16 from the burner 12. The first collection chamber 20has another opening 42 directly opposite opening 40. Opening 42 connectsfirst collection chamber 20 with second collection chamber 30. The finerspheroidized 24 industrial slag 16 microspheres continue their flightand are propelled through opening 42 into the second collection chamber.Opening 44 is a vent employed to allow the escape of gas and dustparticles.

In order to achieve optimal continuous fluid extraction from a well, itis desirable to maintain zonal isolation of the fluids within the wellbore. Lightweight cement slurries are used to obtain this optimal zonalisolation within the well bore. Light weight slurries may be formed fromthe hollow ceramic microspheres of the present disclosure.

TABLE 1 Oxide Blast Iron-nickel slag Iron-nickel slag (% by weight)Furnace Slag (reduction) (smelting) CaO 19-42 50-60 0-1 SiO₂ 32-40 14-6040-50 Al₂O₃ 11-30 10-15 2-5 MgO  8-19  7-10 30-40 Fe₂O₃ 0-5  3-15 10-20SO₃ 1-5  1-10 0-1 K₂O 0-1 0-1 0-1 Na₂O  0-15 0-1 0-1 NiO 0 0-1 0-1Others 1-2 0-1 0-4

Table 1 shows the chemical composition of the industrial slags used forthe present disclosure. As shown in Table 1, by product slag from themanufacturing process of iron nickel alloys contain less than 1% w/w ofmetallic nickel. The iron-nickel smelting slag is produced at the firststage of the iron manufacturing process when the natural ore is exposedto a carbon source and high temperatures. The resultant slag byproductis cooled by water and collected/stored for disposal. The iron-nickelreduction slag is produced during the second stage of the ironmanufacturing process when the resultant iron alloy collected from thesmelting stage is further processed in order to remove contaminants. Theresultant slag byproduct is cooled in air and collected/stored fordisposal.

EXAMPLE 1

Hollow and/or cellular microspheres of the present invention may beformed from blast furnace slag having a composition as detailed in Table1.

BFS having a concentration of about 19% w/w to about 42% w/w CaO, about32% w/w to about 40% w/w SiO2, about 11% w/w to about 30% w/w Al2O3,about 8% w/w to about 19% w/w MgO, about 0% w/w to about 5% w/w Fe2O3,about 1% w/w to about 5% w/w SO3, about 0% w/w to about 1% w/w K2O, andabout 0% w/w to about 15% w/w Na2O, is ground by any method which iswell known within the art to a particle size of about to a particle sizeof less than about 150 microns.

The ground BFS is then manufactured to microspheres by spheroidization,such as the slag spheroidization device of FIG. 1.

Ground BFS is fed to vibration feeder 14. As the ground BFS exitsvibration feeder 14 it is contacted by a flame. The flame is supplied bya glass bench burner 12. The burner 12 propels a gas/oxygen mix flame ofabout 1200° C. to about 2500° C. into the ground BFS as it falls fromvibration feeder 14. The ground BFS is molten by pyrolization.

As the molten ground BFS particles are propelled by burner 12, theybegin to rapidly air cool and are spheroidized. The spheroidized BFS ofa coarser nature and higher density losses its burner 12 propulsion at afaster rate. As a result, these coarser spheroidized BFS microspheressettle in the first collection chamber 20 at a distance that is closerto the burner 12.

Most of the spheroidized BFS microspheres are of a finer nature, have alower density and are hollow. These microspheres are generally hollowedby the decomposition of the sulphur, carbon and/or water dissolved inthe vitreous matrix of the slag. As the slag is introduced to the burner12, the sulphur, carbon and/or water dissolved in the vitreous matrix ofthe slag decompose generating gas, such as CO2, SO3 or H2O. Thegeneration of these gases by the heat of burner 12 permits theproduction of hollow and/or cellular microspheres.

These BFS microspheres are propelled from burner 12 and tend to maintaintheir propulsion for a longer distance. As a result, these finer andhollow spheroidized BFS microspheres settle at a distance that isfurther away from burner 12.

Once the hollow spheroidized BFS microspheres settle in the secondcollection chamber 32, they may be collected and used to make a cementslurry. These hollow and/or cellular BFS microspheres have a density ofless than about 16.7 lbs/g (pound/gallon) (2000 kg/m3 (kilogram/cubicmeter)), preferably between about 7.5 lbs/g to about 16.2 lbs/g (about900 kg/m3 to about 1940 kg/m3), and a controlled particle size ofbetween about 40 microns to about 125 microns.

TABLE 2 Concentration Materials (lbm/bbl) Caustic Soda 8.00 Soda Ash16.00 Silica sand 27.80 Blast Furnace Slag (ground 325 mesh, 45 μm)125.95 Ceramic microspheres from BFS 152.05 Dispersing agent 0.50 Water51.54 Water base semidispersed mud (8.6 lb/g) 85.03

Table 2 illustrates a possible composition for a Mud-to-Cement (MTC)slurry with a density of 11.11 lbs/g (1332 kg/m3). The MTC slurry uses62% of field water base mud with a density of 8.6 lbs/g (1030.5 kg/m3).

EXAMPLE 2

Solid and/or massive microspheres of the present invention may be formedfrom iron-nickel slag having a composition as detailed in Table 1.

The iron-nickel slag of the present disclosure may have twocompositions.

Composition 1 is formed by reduction having a concentration of about 50%w/w to about 60% w/w CaO, about 14% w/w to about 60% w/w SiO2, about 10%w/w to about 15% w/w Al2O3, about 7% w/w to about 10% w/w MgO, about 3%w/w to about 15% w/w Fe2O3, about 1% w/w to about 10% w/w SO3, about 0%w/w to about 1% w/w K2O, about 0% w/w to about 1% w/w Na2O, and about 0%w/w to about 1% w/w NiO.

Composition 2 is formed by fusion having a concentration of about 0% w/wto about 1% w/w CaO, about 40% w/w to about 50% w/w SiO2, about 2% w/wto about 5% w/w Al2O3, about 30% w/w to about 40% w/w MgO, a about 10%w/w to about 20% w/w Fe2O3, about 0% w/w to about 1% w/w SO3, about 0%w/w to about 1% w/w K2O, about 0% w/w to about 1% w/w Na2O, and about 0%w/w to about 1% w/w NiO.

Dependent upon the desired composition of the final microsphere productbeing manufactured, Composition 1 or Composition 2 is ground by anymethod which is well known within the art to a particle size of lessthan about 150 microns.

The slag composition is then manufactured to microspheres byspheroidization, such as the slag spheroidization device of FIG. 1.

The ground iron-nickel slag composition of choice is fed to vibrationfeeder 14. As the ground iron-nickel slag composition exits vibrationfeeder 14 it is contacted by a flame. The flame is supplied by a glassbench burner 12. The burner 12 propels a gas/oxygen mix flame of about1200° C. to about 2500° C. into the ground iron-nickel slag compositionas it falls from vibration feeder 14. The ground iron-nickel slagcomposition is molten by pyrolization.

As the molten iron-nickel slag composition particles are propelled byburner 12, they begin to rapidly air cool and are spheroidized. Most ofthe spheroidized iron-nickel slag composition is of a coarser naturewith a higher density and it losses its burner 12 propulsion at a fasterrate. As a result, the coarser spheroidized iron-nickel slag compositionmicrospheres settle in the first collection chamber 20 at a distancethat is closer to the burner 12.

Few of the spheroidized iron-nickel slag composition microspheres are ofa finer nature.

Once the solid spheroidized iron-nickel slag composition microspheressettle in the first collection chamber 20, they may be collected andused to make a cement slurry. These solid and/or massive iron-nickelslag composition microspheres have a density between at least about 20.9lbs/g to about 31.3 lbs/g (about 2500 kg/m3 to about 3750 kg/m3) and acontrolled particle size of about 150 microns to 38 microns.

TABLE 3 Concentration Materials (lbm/bbl) Dry Blend 65/35(cement/Iron-nickel 317.16 reduction microspheres) Antifoam agent 0.29Dispersing agent 0.71 Liquid extender 7.89 Gas control agent 43.42 Water198.32

Table 3 illustrates a possible composition for a tail slurry with adensity of 13.5 lbs/g (1618 kg/m3). The slurry was made with a dry blendas cementing material. The dry blend used in this slurry was formulatedwith 65% w/w of a cement, such as a moderately sulfate-resistant class Hcement (Cement H MSR), and 35% w/w of solid ceramic microspheres. Thesolid ceramic microspheres were made from an iron-nickel reduction slagwith a density of 25.45 lbs/g (3050.0 kg/m3) and a particle size betweenabout 38 microns to 53 microns. The tail slurry illustrated in Table 3shows chemical resistance to CO2 and H2S, gas migration resistance andimproved thermal cycle strength in steam injection wells.

The hollow and cellular microspheres have a density of less than 11lbs/g (1318 kg/m3). The hollow and cellular microspheres of the presentdisclosure may be formulated with additional additives such as glassmicrospheres, alternative BFS microspheres, polymeric beads(polystyrene) or the like. These additional additives may be added tothe slurry in order to reduce the density to much less than 11 lbs/g(1318 kg/m3).

Microspheres made from reduction iron-nickel slag or smeltingiron-nickel slag may be used to alter the chemical resistance and/orpossible expansion effect of the slurry. In addition, the use of theiron-nickel slag composition of the present disclosure in cementslurries may result in the creation of a cement slurry with weakmagnetic properties. Fe2O3, Fe3O4 and MgFe2O4 both components of theiron-nickel slag composition have remnant magnetic phases which may leadto a cement slurry having magnetic rheological properties.

EXAMPLE 3

The hollow BFS microspheres of Example 1 and/or the solid iron-nickelslag composition microspheres of Example 2 above are mixed with a liquidphase that could be used for the construction of steam injection wells.Examples of liquid phases include oil based drilling fluids and waterbased drilling fluids. Preferably the liquid phase is a water baseddrilling fluid, such as water-based muds, fresh water mud, sea watermud, salt mud, brine mud, lime mud, gypsum mud, synthetic mud,semi-dispersed mud and oil-in-water emulsions. The mixture forms aslurry that is activated by reaction with a high pH solution, such ascaustic soda, Portland cement type I, soda ash and/or any additionalelements within the art that may increase the pH of the slurry. In orderto prevent strength retrogression, other compounds such as antifoam,silica flour and additional cementing materials are added to the slurry.These additional cementing materials may include any additives that areused to control cement properties, i.e. mechanical properties, thermalproperties or chemical resistance to H2S or CO2. Examples of additionalcementing materials are set retardants, plasticizers, glassmicrospheres, cementing glasses, fly ash and straightening agents.

The resultant slurries can be a homogenous MTC system which, uponsolidification, possesses increased thermal cycle strength. Theresultant MTC slurries are advantageously deployed into subterraneanwells by any method which is well known within the art.

In order to produce well bore zonal isolation, the ceramic microspheresof the present disclosure may also be used as an alternative to Portlandcement in mud-to-cement (MTC) applications. The use of the microspheresof the present disclosure in MTC applications may also reduce theoperational costs of well cementing activities by reducing theenvironmental impact of the mass consumption of ordinary cementslurries.

The ceramic microspheres of the present disclosure used in cementingapplications have led to the creation of lightweight cement slurriesthat are resistant to elevated temperatures and thermal cycling, such asthose found in steam injection techniques.

The ceramic microspheres of the present invention may be implemented inother possible applications. The final physical and chemicalcharacteristics of the microspheres of the present invention may beapplied to conventional cementing well technology, blended cementmanufacturing, bridge construction, dam construction, onshore/offshoreconstruction, coastal infrastructure, and any application that maybenefit from the cementitious/pozzolanic properties of the presentinvention.

It is to be understood that the invention is not limited to theillustrations described and shown herein, which are deemed to be merelyillustrative of the best modes of carrying out the invention, and whichare susceptible of modification of form, size, arrangement of parts anddetails of operation. The invention rather is intended to encompass allsuch modifications which are within its spirit and scope as defined bythe claims.

1. An apparatus for manufacturing ceramic microspheres from industrialslag, comprising: a glass bench burner: a vibration feeder arranged tofeed industrial slag to the glass bench burner; a first collectionchamber having an inlet, an outlet and a first collection zone, theinlet being aligned with the glass bench burner to receive a stream ofpropelled industrial slag from the glass bench burner; a secondcollection chamber having an inlet which is aligned with the outlet ofthe first collection chamber, whereby a first portion of the propelledindustrial slag falls into the first collection zone, and second portionof the propelled industrial slag, separate from the first portion,passes through the outlet of the first collection chamber and the inletof the second collection chamber; and a wall fixed between the firstcollection chamber and the second collection chamber, wherein the outletof the first collection chamber is defined in the wall, whereby thefirst portion of propelled industrial slag hits the wall and remains inthe first collection chamber, and the second portion passes through theoutlet of the first collection chamber and the inlet of the secondcollection chamber into the second collection chamber.
 2. The apparatusof claim 1, wherein the glass bench burner produces a gas/oxygen mixflame of about 1200° C. to about 2500° C.
 3. The apparatus of claim 2,wherein the gas is a natural gas.
 4. The apparatus of claim 1, whereinthe first collection chamber is directly connected to the flame of theburner at one end and is directly connected to the second collectionchamber at the opposite end.
 5. The apparatus of claim 1, wherein thesecond collection chamber has a discharge vent.